Foam composition for a disposable single use applicator assembly with a chemical composition

ABSTRACT

The applicator assembly delivers a cosmetic, health, or hygiene chemical composition in an active state to the user for a disposable single use. The applicator assembly includes a wrapper, and an insert. The insert holds the chemical composition, and the insert is made of a foam composition compatible with the chemical composition. The system and method for manufacturing the assembly is a web conversion process for the chemical composition and foam composition of the assembly. The insert body of the assembly is made of a foam composition compatible with the cosmetic or other hygiene or medical treatment of the chemical composition and the manufacturing process. The foam composition includes a reaction product of water, clay, polyacrylate, silane, methanol, ethylenediamine, and polyurethane prepolymer.

CROSS-REFERENCE TO RELATED APPLICATIONS

See Application Data Sheet.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR ASA TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)

Not applicable.

STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINTINVENTOR

Not applicable.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to cosmetics, health, and hygiene productsto be packaged for disposable single use. More particularly, the presentinvention relates to disposable single use applicator assemblies with achemical composition. The present invention also relates to the chemicalcomposition in the assembly and the foam composition forming theapplicator of the assembly. The present invention further relates to thesystem and method for manufacturing the disposable single use applicatorassembly.

2. Description of Related Art Including Information Disclosed Under 37CFR 1.97 and 37 CFR 1.98

Various industries have developed systems and methods for disposablesingle use packets. The toiletry appliance of U.S. Pat. No. 1,791,351,issued to Chase on 3 Feb. 1931, and the make-up applicator of U.S. Pat.No. 1,888,314, issued to Framke on 22 Nov. 1932, are two early examplesin the hygiene and cosmetics fields. U.S. Pat. No. 2,598,323, issued toWagar on 27 May 1952, is an early example of an embossing machine tomanufacture disposable single use packets.

More recent patents cover developments in the material selection ofdisposable single use packets. U.S. Pat. No. 6,062,234, issued toFinocchiaro et al on 16 May 2000, and U.S. Pat. No. 6,312,181, issued toJoulia on 6 Nov. 2001, disclose disposable single use packets formed ofparticular materials. U.S. Pat. No. 7,514,071, issued to Simon on 7 Apr.2009, and U.S. Pat. No. 8,087,417, issued to Dobler et al on 3 Jan.2012, describe substrates selected for the adhering different cosmeticchemical compositions in a disposable single use packet. U.S. Pat. No.9,113,692, issued to Khan et al on 25 Aug. 2015, and U.S. Pat. No.9,301,589, issued to Griffiths et al on 5 Apr. 2016, disclose specificsfor the material selection of the chemical composition and thesubstrate.

Furthermore, several patents and publications relate to the developmentof methods for assembling disposable single use packets.

U.S. Pat. No. 5,647,941, issued to Gunderman et al on 15 Jul. 1997,discloses a method for making a lipstick sampler, and U.S. Pat. No.6,190,730, issued to Matsos on 20 Feb. 2001, describes another method bythe same group of inventors for U.S. Pat. No. 5,647,941, which includescosmetics besides lipstick. U.S. Pat. No. 6,260,887, issued to Fujii on17 Jul. 2001, and U.S. Pat. No. 7,297,285, issued to Chang on 20 Nov.2007, disclose embossing methods for adhering chemical compositions on asubstrate, which can be adapted for disposable single use packets. U. S.Patent No. 2008/0022866, published for Frank et al on 31 Jan. 2008, andU. S. Patent No. 2008/0022821, published for Henrik on 31 Jan. 2008 bothdisclose the manufacturing machine for assembling disposable single usepackets. More recently, U. S. Patent No. 2014/0195038, published forBalleis et al on 10 Jul. 2014, describe aspects of a web conversionfeature in the overall manufacturing process.

It is an object of the present invention to provide a disposable singleuse applicator assembly with a chemical composition.

It is another object of the present invention to provide a disposablesingle use applicator assembly compatible with a web conversionmanufacturing process.

It is still another object of the present invention to provide adisposable single use applicator assembly with a cosmetic, health orhygiene chemical composition and an applicator with a chemicalcomposition for delivery of the cosmetic, health, or hygiene chemicalcomposition in an active state to the user.

It is still another object of the present invention to provide adisposable single use applicator assembly with components that maintainalignment during the manufacturing process before sealing.

It is another object of the present invention to provide an embodimentof an applicator assembly to store a limited amount of a cosmetic.

It is still another object of the present invention to provide anembodiment of an applicator assembly to store an amount of a cosmeticfor a single application of the cosmetic.

It is yet another object of the present invention to provide anembodiment of an applicator assembly to store a limited amount of acosmetic in a disposable and portable container.

It is another object of the present invention to provide an applicatorassembly to store and carry cosmetics in a simple, easy, and inexpensivecontainer.

It is an object of the present invention to provide a chemicalcomposition for a disposable single use applicator assembly.

It is another object of the present invention to provide a chemicalcomposition compatible with a web conversion manufacturing process for adisposable single use applicator assembly.

It is still another object of the present invention to provide achemical composition that adheres to an applicator during themanufacturing process so as to maintain alignment before sealing.

It is still another object of the present invention to provide achemical composition that dries during the manufacturing process beforesealing.

It is an object of the present invention to provide a foam compositionfor an applicator or insert of a disposable single use applicatorassembly.

It is another object of the present invention to provide a foamcomposition compatible with a web conversion manufacturing process for adisposable single use applicator assembly.

It is still another object of the present invention to foam compositionthat can adheres a chemical composition during the manufacturing processbefore sealing.

It is still another object of the present invention to provide a foamcomposition that maintains alignment during the manufacturing processbefore sealing.

It is an object of the present invention to provide a disposable singleuse applicator and packaging assembly.

It is an object of the present invention to provide a system and methodfor manufacturing a disposable single use applicator assembly.

It is another object of the present invention to provide a webconversion method of manufacturing a disposable single use applicatorassembly.

It is another object of the present invention to provide a system toperform the web conversion method of manufacturing a disposable singleuse applicator assembly.

It is still another object of the present invention to provide a systemand method of manufacturing a disposable single use applicator assemblyfor delivery of the cosmetic, health, or hygiene chemical composition inan active state to the user.

It is still another object of the present invention to provide a systemand method of manufacturing a disposable single use applicator assemblymaintaining alignment during the web conversion of the manufacturingprocess.

These and other objectives and advantages of the present invention willbecome apparent from a reading of the attached specifications andappended claims.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the present invention include the applicator assembly todeliver a chemical composition in an active state for a disposablesingle use. The chemical composition can be cosmetics or a medical orhygiene related substance. The assembly includes an applicator forsupporting the chemical composition during manufacturing, storage in theassembly, and administering the chemical composition. The assemblyincludes a wrapper and an insert. The insert holds the chemicalcomposition, and the insert is made of a foam composition compatiblewith the chemical composition. The system and method for manufacturingthe assembly is a web conversion process for the chemical compositionand foam composition of the assembly.

The present invention includes the foam composition for the insert bodyof the assembly. The foam composition must be compatible with thechemical composition and the manufacturing process. With the insert bodyas the holder of the chemical composition, the foam composition musthold the chemical composition when first dispensed for packaging andwhen stored for longer periods of time in the assembly. Additionally,the insert body must retain strength to be used as the applicator foradministering the chemical composition, after the assembly has beenstored until use. The foam composition can include a reaction product ofwater, clay, polyacrylate, silane, methanol, ethylenediamine, andpolyurethane prepolymer. The foam composition further describesembodiments of the assembly and method of manufacture. The constructionof the assembly must be compatible with the chemical composition on theapplicator portion of the insert body, including different applicatorportions of the assembly. The construction of the assembly must becompatible with different chemical compositions on the applicatorportion of the insert body, including a plurality of chemicalcompositions for a single dose. For a cosmetic, a single application mayinclude foundation as one chemical composition and bronzer as anotherchemical composition. The applicator portion of the foam compositionmust be compatible with each of those chemical composition as arrangedon the assembly. Furthermore, the timing of dispensing the chemicalcomposition on the foam composition in the manufacturing process mustpreserve the active state and sometimes vibrancy of color of a makeupeffect.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded perspective view of an embodiment of an assemblyfor storing and transporting a chemical composition, according to thepresent invention.

FIG. 2 is an upper perspective view of the packaged configuration of theassembly, according to an embodiment of the present invention.

FIG. 3 is a front elevation view of a top sheet of the assembly,according to an embodiment of the present invention.

FIG. 4 is a front elevation view of a bottom sheet of the assembly,according to an embodiment of the present invention.

FIG. 5 is a front elevation view of an insert of the assembly, accordingto an embodiment of the present invention.

FIG. 6 is a front elevation view of the packaged configuration of FIG.2.

FIG. 7 is a side elevation view of a system to manufacture an assembly,according to an embodiment of the present invention.

FIG. 8 is a top plan view of the system to manufacture an assembly,according to FIG. 7.

FIG. 9 is an end elevation view of the system to manufacture anassembly, according to FIG. 7.

FIG. 10 is an enlarged side elevation view of a portion of a system tomanufacture an assembly, according to an embodiment of the presentinvention.

FIG. 11 is an enlarged side elevation view of another portion of asystem to manufacture an assembly, according to an embodiment of thepresent invention.

FIG. 12 is an enlarged side elevation view of still another portion of asystem to manufacture an assembly, according to an embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

The overall present invention includes the disposable single useapplicator assembly, the chemical composition for the assembly, and thefoam composition for the assembly with the chemical composition. Thesystem to manufacture the assembly, and the method for manufacturingwith the system are also included as embodiments.

Disposable Single Use Applicator Assembly with a Chemical Composition

Embodiments of the present invention include the assembly 10 of FIGS.1-6 and 10-12. The assembly 10 stores and transports a chemicalcomposition 200, 210, 220. A set amount of the chemical composition 200,210, 220, corresponding to a single dose of medication or singleapplication of a cosmetic, is packaged on an applicator within theassembly 10. The medication can be an ointment or antiseptic, or othertopical treatments. The cosmetic can include a face, skin, eye, or otherbeauty effect, and multiple cosmetics can be stored and transported inthe assembly. Chemical compositions 200, 210, 220 can have anycombination of being the same or different from each other. Two or threedifferent chemical combinations are possible, such as chemicalcomposition 200 and chemical composition 210 being foundation, andchemical composition 220 being bronzer. The assembly 10 providesconvenience and versatility.

According the FIGS. 1-6, the assembly 10 includes a wrapper 20 having atop sheet 30 and a bottom sheet 40, and an insert 50 having a topsurface 52 and a bottom surface 54. FIG. 1 shows an exploded view, whileFIGS. 2 and 6 show a packaged configuration. The insert 50 is comprisedof an insert body 60 with a handle portion 62 and an applicator portion64, as also seen in FIG. 5 without the chemical composition 200, 210,220. The top sheet 30 of FIG. 3 is sealed to the bottom sheet 40 of FIG.4 as shown in FIG. 1. The top sheet 30 and the bottom sheet 40 form aborder 22 along a perimeter of the top sheet 30 and the bottom sheet 40.The insert 50 being positioned between the top sheet 30 and the bottomsheet 40. FIGS. 1-6 show the border 22 aligned with the applicatorportion 64 only so as to maintain the insert 50 in place within thewrapper 20.

In some embodiments, the assembly 10 includes a tab 24 being comprisedof an incision 26 in the border 22. The incision 26 is within the border22 so that the insert 50 remains sealed within the assembly 10 and theborder 22. The tab 24 can be used to separate the top sheet 30 and thebottom sheet 40. The tab 24 tears the border 22, so that the top sheet30 and bottom sheet 40 no longer seal the insert 50 in the assembly 10.

FIG. 5 shows an embodiment of the insert body 60 having rotationalsymmetry of having at least four cyclic groups 66. In this frontelevation view, the clover shape has four cyclic groups, but otherembodiments may have different rotational symmetry. In the presentinvention, the handle portion 62 corresponds to only one cyclic group66. The border 22 is aligned with the applicator portion 64 only so asto maintain the insert 50 in place within the wrapper 20, such that theborder 22 is aligned with the cyclic groups 66 corresponding to theapplicator portion 64. In some embodiments, the border can be alignedwith cyclic groups 66 corresponding to the application portion 64directly opposite the handle portion 62. Alternatively, the border 22may align with at least one cyclic group 66 corresponding to theapplication portion 64 and directly opposite the handle portion 62. Instill another embodiment, the border 22 aligns with parts of cyclicgroups 66 corresponding to the application portion 64 corresponding to aside 68 of the insert body 60 opposite to the handle portion 62, as inFIG. 1.

When the insert 50 is separated from the assembly 10 for use, the handleportion 62 is accessible on the top surface 52 and on the bottom surface54. The bottom surface 54 can be smooth, and the top surface 52 can beidentical to the bottom surface 54 or different with a different texturefor holding the chemical composition 200, 210, 220. Alternatively, thehandle portion 62 can further comprise a gripping means 58, such as apad, indentation, or tacky element. The gripping means 58 is sufficientfor gripping by the user. FIG. 1 shows the gripping means 58 as a smoothsurface.

FIG. 1 shows the embodiment of the insert 50 further comprising: a setamount of a chemical composition 200, 210, 220, corresponding to asingle dose or single application. The set amount is positioned on theapplicator portion 64. When the insert body 60 has rotational symmetryhaving at least four cyclic groups 66, the handle portion 62 correspondsto only one cyclic group 66, and the set amount of chemical composition200, 210, 220 is divided between each cyclic group 66 of the applicatorportion 64. There are embodiments with the set amount corresponds to aplurality of set amounts, such as a plurality of different cosmetics fora single application. In this embodiment, the chemical composition is aplurality of chemical compositions 200, 210, 220, and when the insertbody 60 has rotational symmetry of at least four cyclic groups 66, eachset amount of each chemical composition 200, 210, 220 is positioned on acorresponding cyclic group 66 of the applicator portion 64. Eachcosmetic is positioned on a respective cyclic group 66 of the applicatorportion 64 separate from other cosmetics.

Chemical Composition for a Disposable Single Use Applicator Assembly

Embodiments of the chemical composition 200, 210, 220 are shown inFIG. 1. As a medication or cosmetic, the chemical composition 200, 210,220 of the present invention must be compatible with the insert body 60and suitable for disposable single use storage and transport. Not allchemical compositions will remain active and viable, under theconditions in the assembly 10 or under the conditions for manufacturingthe assembly 10. In the field of cosmetics, the chemical compositionmust retain consistency for reliable application and color for theproper makeup effect. The vibrancy of the makeup effect can be achievedunder the conditions in the assembly 10 and under the conditions formanufacturing the assembly 10.

The present invention includes a chemical composition 200, 210, 220comprising 55-70 weight percent of amorphous silica, 4-12 weight percentof a white adhesive agent, 1-30 weight percent of a coloring agent, and0.5-4.0 weight percent a first aromatic preservative agent. Theamorphous silica is an absorbing agent and a thickening agent. The whiteadhesive agent can be magnesium myristate in some embodiments. In thepresent invention, the white adhesive agent allows for storage in theassembly 10 and adhesion to the insert body 60 without affecting color.Although some adhesive agents can have color, the present inventionachieves the desired vibrancy of color without a colored adhesive agent.The coloring agent can be iron oxides, which have the known feature ofcoloring cosmetics. However, the chemical compositions 200, 210, 220 tohave level of color adhered to the insert body 60, sealed in a wrapper20 and manufactured by the system 240 in FIGS. 7-12 are embodiments ofthe present invention. The first aromatic preservative agent can becomprised of a vegetable based essential oil fraction. The scent andactivity of the chemical composition are set for consistency under theconditions of the assembly 10.

In some embodiments, the chemical composition 200, 210, 220 furthercomprises equal to or less than 5 weight percent of a sealing agent,such as phenyl trimethicone. The sealing agent can be based on silica tobe compatible in the chemical composition 200, 210, 220. The sealingagent sets viscosity and prevents foaming, which relates to storageconditions on the insert body 60.

The chemical composition can be further comprised of equal to or lessthan 1 weight percent of a preservative agent. In addition to the firstaromatic preservative agent, another preservative agent can be added toprevent development of microorganisms. Again, in the sequence ofmanufacturing, the chemical composition 200, 210, 220 can be exposed toair with microorganisms. In some embodiments, this other preservativeagent is Potassium sorbate.

The chemical composition can also be comprised of equal to or less than2 weight percent of a second aromatic preservative agent. Just as therecan be additional preservative agent, there can also be a secondaromatic preservative agent. The chemical composition 200, 210, 220finds the synergy of vegetable based first aromatic preservative agentwith another preservative agent and the second aromatic preservativeagent, such as phenoxyethanol. The redundancy is beyond the prior artand allows the chemical composition 200, 210, 220 to be contained in theassembly 10.

Embodiments of the chemical composition also include equal to or lessthan 20 weight percent of a bulking agent, such as syntheticfluorophlogopite. The bulking agent adjusts viscosity and can supportthe amorphous silica as the thickening agent. The range and overlap ofredundancy sets the chemical composition 200, 210, 220 beyond the priorart disclosures of these chemical compounds in isolation. Althoughbalancing any chemical composition for a desired effect is known, thepresent invention selects redundancies in particular ranges and overlapfor the desired effect in an innovative combination related to theassembly 10 and manufacture of the assembly 10. The chemical composition200, 210, 220 is an embodiment of the present invention.

Foam Composition for a Disposable Single Use Applicator Assembly with aChemical Composition

Embodiments of the foam material 160 are shown in FIGS. 1, 7 and 10. Theinsert body 60 is formed by the foam material 160. The foam material iscomprised of a foam composition 230. Similar to the chemical composition200, 210, 220, the insert body 60 is comprised of a foam composition 230suitable for disposable single use storage and transport. Not all foamcompositions will support the chemical compositions 200, 210, 200 asactive and viable, under the conditions in the assembly 10 or under theconditions for manufacturing the assembly 10. In the field of cosmetics,the foam composition must have durability, hardness, and absorbency tobe used in a manufacturing process and hold a chemical composition. Inthe present invention, the foam composition 230 must have thecompatibility with the chemical composition 200, 210, 220 of theassembly 10 during manufacturing and storage so as to retain consistencyfor reliable application and activity for the proper makeup effect.

The present invention includes a foam composition 230 comprising areaction product of water, clay, polyacrylate, silane, methanol,ethylenediamine, and polyurethane prepolymer. The foam composition 230is hydrophilic so that the absorption of the chemical composition 200,210, 220 is limited. The foam composition 230 has a melting pointgreater than 350 F and a specific gravity of 0.3 to 0.5 for thedurability and hardness suitable for the assembly 10 and manufacture ofthe assembly 10. The embodiments of the polyurethane foam of the presentinvention is compatible with the range and overlap of redundancy in thechemical composition 200, 210, 220 beyond the prior art disclosures ofwater, clay, polyacrylate, silane, methanol, ethylenediamine, andpolyurethane prepolymer in isolation. Although any foam composition canbe developed for desired durability, hardness, and absorbency, thepresent invention selects a reaction product in combination withparticular ranges and overlap of a chemical composition 200, 210, 220 inthe assembly 10. The foam composition 230 is another embodiment of thepresent invention.

System to Manufacture a Disposable Single Use Applicator Assembly with aChemical Composition

Embodiments of the present invention include the system 240 formanufacturing the assembly 10 of FIGS. 1-6 and 10-12. The system 240 isshown in FIGS. 7-12 as a web conversion device. The assembly 10 isformed from rolls of material, top sheet material 130, bottom sheetmaterial 140, and foam material 160, and there are cutting, sealing, andconveying steps producing the web materials as a perforated top materialsheet 131, a perforated bottom material sheet 141, and perforated foammaterial sheet 161 to be tracked on course through the system 240.Additionally, there is the chemical composition 200, 210, 220 to beinserted into the system 240 for dispensing, curing, and sealing incoordination with the regular web conversion steps. The system 240 ofthe present invention elevates a web conversion device for a disposablesingle use applicator assembly with a chemical composition.

FIGS. 7-9 show the system 240 for manufacturing the assembly 10,comprising a first roll 100 of wrapper material 120 mounted in a firstdirection 98. The first roll 100 dispenses the wrapper material 120 inthe first direction 98 in FIG. 9. The wrapper material 120 splits into atop sheet material 130 and a bottom sheet material 140 in FIGS. 7 and10. The split of the wrapper material 120 enables the assembly 10 to bealigned according to distance. The coordination and matching of markingsfor each assembly 10 on the top sheet material 130 and bottom sheetmaterial 140 only need to travel the same distance in order to bealigned. Thus, the control and monitoring of the system 240 can be moreefficient. There are not two separate rolls to be managed at differentdispensing rates, and there is no additional scanning to match themarkings on two different rolls, when cutting or sealing in the presentinvention.

As such, the system 240 further comprises a lower turn bar 103 below thefirst roll 102 so as to conveying the bottom sheet material 140 in asecond direction 96 orthogonal to the first direction 98, and an upperturn bar 101 above the first roll 102 so as to conveying the top sheetmaterial 130 in a third direction 94 orthogonal to the first direction98 and opposite and parallel to the second direction 96. There is aplurality of upper rollers 109 switching the top sheet material 130between the third direction 94 and the second direction 96, and there isa plurality of lower rollers 107 switching the bottom sheet material 140between the second direction 96 and the third direction 94. The system240 sets the upper rollers 109 and the lower rollers 107 to match thedistance traveled by the top sheet material 130 and the bottom sheetmaterial 140, so that the markings and labels of each assembly 10 remainaligned.

There is a second roll 102 of foam material 160 mounted orthogonal tothe first roll 100. The second roll 102 dispenses the foam material 160in the third direction 94 along the system 240. The second roll 102 ismounted at one end of the system 240. FIGS. 7 and 10 show a foam cutter105 aligned with the second roll 102 so as to cut the foam material 160into a plurality of insert bodies 60 and a perforated foam materialsheet 161. The foam material 160 matches the bottom sheet material 140in the third direction 94 at the foam cutter 105. In some embodiments,the foam cuter is a die cutter but other known cutters are possible. Thefoam material 160 is above the bottom sheet material 140.

In some embodiments, there is a third roll 104 below the second roll 102so as to store the perforated foam material sheet 161. The perforatedfoam material sheet 161 is a web material to be recovered so as to avoidaffecting alignment of the other sheet materials 130, 140 and the insertbodies 60 cut from the foam material 160. FIGS. 7 and 10 show theperforated foam material 161 conveyed in the second direction 96 awayfrom the plurality of insert bodies 60 and between the foam material 160to be cut and the bottom sheet material 140. The foam material 160 andperforated foam material sheet 161 are isolated from the bottom sheetmaterial 130 at the foam cutter 105.

There can also be a position scanner 111 positioned above the bottomsheet material 140 after the foam cutter 105. The position scanner 111monitors alignment of the insert bodies 60. Each insert body 60 isaligned by being laid on the bottom sheet material 140 while matchingthe bottom sheet material 140 in the third direction 94. The insertbodies 60 pass the position scanner 111 so as to confirm alignment ofeach insert body 60 on the bottom sheet material 140. Each insert body60 is removable adhered to the bottom sheet material 140, so each insertbody 60 is able to move or shift. In some embodiments, staticelectricity or other removably adhering means is used to maintainalignment on the bottom sheet material 140.

FIGS. 7 and 10 also show a dispenser 106 having the chemical composition200, 210, 220 stored within the dispenser 106. The chemical composition200, 210, 220 is suitable to be stored and dispensed from the dispenser106. The chemical composition 200, 210, 220 can be loaded and stored ascartridges or pumped to the dispenser 106 from a larger supply. Theviscosity and activity of the chemical composition 200, 210, 220 iscompatible with the dispenser 106 in the system 240. The dispenser 106is positioned above each insert body 60 and the bottom sheet material140 and after the foam cutter 105. The dispenser 106 move to match thebottom sheet material 140 in the third direction 94 so that the chemicalcomposition 200, 210, 220 can be delivered or sprayed on the insert body60, while moving across and along the bottom sheet material 140, whichis also moving in the third direction 94. A set amount of the chemicalcomposition 200, 210, 220 and a respective insert body 60 form an insert50 for each insert body 60.

For some embodiments of FIGS. 7 and 10, the dispenser 106 includes asprayer 113 so as to deliver the set amount of the chemical composition200, 210, 220 corresponding to a single dose for each insert 50. The setamount is positioned on the applicator portion 64, and the set amount isdivided between each cyclic group 66 of the applicator portion 64. Thedispenser 106 is movable across the bottom sheet material 140 and eachinsert body 60 for a delivery time period. The delivery time period isthe time needed to dispense the chemical composition 200, 210, 220 threetimes in FIGS. 1, 7 and 10. The delivery time period corresponds to adistance between the foam cutter 105 and a flatbed heat seal packager108. The dispenser 106 is movable in the second direction 96 to alignwith another insert body 60 upstream toward the foam cutter 105, afterreaching the flatbed heat seal packager 108. The dispenser 105 canspraying any pattern of chemical composition 200, 210, 220 as the sameor different compositions. The dispenser 105 moves to spray on eachinsert body 60 and to match the movement of the bottom sheet material140 as a conveyor belt.

As shown in FIGS. 7 and 11, the system 240 further comprises a firstscanner 114. The inserts 50 now need to be checked so as to confirmalignment on the bottom sheet material 140, proper dispensing of thechemical composition 200, 210, 220, and alignment of the chemicalcomposition 200, 210, 220 on the insert body 60. For each insert 50, thefirst scanner 114 is positioned away from the dispenser 106 and alongthe bottom sheet material 140 in the third direction 94. The firstscanner 114 can be selected from a group consisting of a vision sensor,a splice sensor, and another sensor. FIG. 11 shows a vision sensor. Aspart of the web conversion again, the alignment of the insert 50 withchemical composition 200, 210, 220 needs confirmation because the bottomsheet material 140 is going to be cut later in the process. In someembodiments, there is a plurality of first scanners 114. More than onescanner can perform the monitoring of alignment, and any combination ofa vision sensor, a splice sensor, and another sensor can be selected.

Embodiments of the system 240 are further shown in FIGS. 7 and 12 withthe flatbed heat seal packager 108 positioned along the bottom sheetmaterial 140 in the third direction 94 after the dispenser 106. Theflatbed heat seal packager 108 is also movable in the third direction 94and matches both the bottom sheet material 140 and the top sheetmaterial 130 in the third direction 94. The upper turn bar 101 and theupper rollers 109 align the top sheet material 130 above the insert 50and the bottom sheet material 140. The top sheet material 130 from theupper turn bar 101 to the flatbed heat seal packager 108 matches thebottom sheet material 140 from the lower turn bar 103 to the flatbedheat seal packager 108 in distance traveled so that the markings andlabels on the wrapper material 120 remain aligned for each assembly 10.The flatbed heat seal packager 108 seals the top sheet 30 of the topsheet material 130 to a bottom sheet 40 of the bottom sheet material 140around each insert 50 so as to form the border 22 along a perimeter ofeach insert 50. Each insert 50 is now positioned between the top sheet30 and the bottom sheet 40, while the flatbed heat seal packager 108matches the bottom sheet material 140 and the top sheet material 130 inthe third direction 94. The border 22 is aligned with the applicatorportion 64 to maintain the insert 50 in place within the border 22.

FIG. 12 shows the flatbed heat seal packager 108 as movable along thebottom sheet material 140 and the top sheet material 130 for a packagingtime period. The packaging time period is the time to seal and form theborder for each insert 50 in the flatbed heat seal packager 108. Thepackaging time period also corresponds to a distance traveled by theflatbed heat seal packager 108 between the dispenser 106 and a sheetcutter 117. The flatbed heat seal packager 108 moves back in the seconddirection 96 to align with another insert 50 upstream toward thedispenser 106, after reaching the sheet cutter 117 and completing theborders 22 on the inserts 50. The flatbed heat seal packager 108 movesin the third direction 94 and second direction 96.

As shown in FIGS. 7 and 12, the system 240 further comprises a secondscanner 116 positioned between the flatbed heat seal packager 10 and thesheet cutter 117 in the third direction 94. The inserts 50 with borders22 now need to be checked so as to confirm the seal and border 22 of thetop sheet material 130 and the bottom sheet material 140. For eachinsert 50 with border 22, the second scanner 116 is positioned away fromthe flatbed heat seal packager 108 and along the bottom sheet material140 in the third direction 94. The second scanner 116 can be selectedfrom a group consisting of a photoelectric sensor, a vision sensor, asplice sensor, and another sensor. FIG. 12 shows a photoelectric sensor.As part of the web conversion, the seal of the insert 50 by the border22 needs confirmation because the top sheet material 130 and the bottomsheet material 140 are going to be cut together next in the process. Thesecond scanner 116 may also include a plurality of scanners incombination.

The embodiment of FIG. 12 shows a nip machine 115 between the flatbedheat seal packager 108 and the sheet cutter 117 in the third direction94. Since each border 22 requires an incision 26 to form the tab 24 ofthe assembly 10, the nip machine 115 cuts the incision 26 within theborder 22, before the borders 22 are cut from the top material sheet 130and the bottom material sheet 140.

The system 240 further comprises the sheet cutter 117 positioned alongthe bottom sheet material 140 and the top sheet material 130 in thethird direction 94 after the flatbed heat seal packager 108. Each border22 is cut from the top sheet material 130 and the bottom sheet material140 so as to form an assembly 10 from each border 22. The cutting alsogenerates a perforated top sheet material 131, and a perforated bottomsheet material 141. Each assembly 10 now comprises a respective insert50 and a wrapper 20 having the top sheet 30 from the top sheet material130 and the bottom sheet 40 from the bottom sheet material 140. Theassemblies 10 are conveyed to an outfeed conveyor 112 moving in thethird direction 96 away from the sheet cutter 117.

FIGS. 7 and 12 also disclose the treatment of the web materials as theperforated top sheet material 131 and the perforated bottom sheetmaterial 141. There can be a fourth roll 110 below the outfeed conveyor112 so as to store the perforated top sheet material 131 and theperforated bottom sheet material 141 together. The perforated top sheetmaterial 131 and the perforated bottom sheet material 141 are recoveredfor disposal, recycling, and to avoid hindering the top sheet material130 and bottom sheet material 140 still being processed by the system240. The perforated top sheet material 131 and the perforated bottomsheet material 141 are conveyed in the second direction 96 away from theoutfeed conveyor 112 and below the outfeed conveyor 112.

Embodiments of the system 240 further include a packing means 170 or asorting means 180 or both. The packing means 170 connects to the outfeedconveyor 112 for placing the assemblies 10 into boxes or sleeves fortransport. The packing means 170 can be manual or any known automatedmachine, such as a collector and boxing machine. Alternatively, therecan be a sorting means 180 separate or cooperative with the packingmeans 170. The sorting means 180 can divide and separate the assemblies10 from the outfeed conveyor 112 into groups. The groups may beassociated with packaging for the packing means 170, such as packing agroup of twelve assemblies 10 in one box. The groups may also beassociated with different chemical compositions 200, 210, 220. Thescanners 111, 114, 116 have detected the contents of the assemblies 10,and the markings and labels on the top sheet 30 and the bottom sheet 40are known. Thus, the sorting means 180 can be manual or any knownautomated machine, such as a swivel arm and different sleeves forgrouping.

FIGS. 7 and 12 also show embodiments with a reject conveyer 118. Thereject conveyer 118 is positioned after the sheet cutter 117 in thethird direction 94. The scanners 111, 114, 116 have been detecting andmonitoring for any errors in the manufacturing process. The system 240maintains and records the position of each insert body 60, correspondinginsert 50, and corresponding assembly 10. So, any error or anomalydetected as an insert body 60, an insert 50, or assembly 10 can betracked as a tagged assembly. When that tagged assembly reaches thereject conveyor 118, the tagged assembly is separated from the otherassemblies 10. The system 240 can detect errors and remove assembliesthat do not meet quality control requirements. The coordination of thecomponents of the system 240 allow for accurate tracking and thepossible use of a reject conveyor 118 as automated quality control.

Method for Manufacturing a Disposable Single Use Applicator Assemblywith a Chemical Composition

Embodiments of the present invention include the method of manufacturingwith the system 240 for the disposable single use applicator assembly 10with a chemical composition 200, 210, 220. The method tracks closely tothe system 240. As shown in FIGS. 7-12, the method of manufacturing,comprises the steps of: mounting a first roll 100 of wrapper material120, dispensing the wrapper material in a first direction 98, splittingthe wrapper material into a top sheet material 130 and a bottom sheetmaterial 140, conveying the bottom sheet material 140 in a seconddirection 96 orthogonal to the first direction 98 by a lower turn bar103, and conveying the top sheet material 130 in a third direction 94orthogonal to the first direction 98 and opposite and parallel to thesecond direction 96 by an upper turn bar 101. The top sheet material 130switches between the third direction 94 and the second direction 96 by aplurality of upper rollers 109, and the bottom sheet material 140switches between the second direction 96 and the third direction 94 by aplurality of lower rollers 107. The method matches the top sheetmaterial 130 and the bottom sheet material 140 from the wrapper material120 orthogonal to components of the system 240, while maintaining thealignment of markings and labels on the top sheet material 130 and thebottom sheet material 140.

Next, the method mounts a second roll 102 of foam material 160orthogonal to the first roll 100, and dispenses the foam material 160 inthe third direction 94. The foam material 160 matches the bottom sheetmaterial 140 in the third direction 94 at a foam cutter 105 aligned withthe second roll 102. The foam material 160 runs above the bottom sheetmaterial 140. When the foam material 160 is cut into a plurality ofinsert bodies 60 and a perforated foam material sheet 161 with the foamcutter 105, the insert bodies 60 are laid on the bottom sheet material140 in motion in the third direction 94. The method aligns each insertbody 60 on the bottom sheet material while matching the bottom sheetmaterial in the third direction.

In this sequence, the system 240 has stored a chemical composition 200,210, 220 in a dispenser 106 positioned after the step of cutting thefoam material 160. The dispenser 106 is positioned above each insertbody 60 and the bottom sheet material 140 after the foam cutter. Themethod includes dispensing the chemical composition 200, 210, 220 fromthe dispenser 106 on each insert body 60 while matching the bottom sheetmaterial 140 in the third direction 94, so as to form an insert 50,corresponding to each insert body 60. A set amount of the chemicalcomposition 200, 210, 220 corresponding to a single dose is deliveredfor each insert 50, and the dispenser 106 matches the bottom sheetmaterial 140 in the third direction 94.

Embodiments of the step of matching the dispenser 106 include moving thedispenser 106 across the bottom sheet material 140 and over each insertbody 60 for a delivery time period. The delivery time period correspondsto a duration of time for the step of dispensing to each insert body 60so as to form each insert 50, and aligning the dispenser 106 withanother insert body 60 upstream toward the foam cutter 105 by moving inthe second direction 94, after the delivery time period of the step ofdispensing. Any pattern by spraying on the insert body 60 is performedwhile matching the dispenser 106 to the bottom sheet material 140 in thethird direction 94.

The method further includes curing the chemical composition 200, 210,220 on the foam material 160 of the insert body 60 with the foammaterial 160 being comprised of a foam composition 230. The chemicalcomposition 200, 210, 220 and the foam composition 230 are cooperativeto complete the step of curing within the time between the dispenser 106and the flatbed heat seal packager 108 and within the distance betweenthe dispenser 106 and the flatbed heat seal packager 108. Each insert 50on the bottom sheet material 140 is conveyed for a conveyer time periodaway from the dispenser 106, the conveyor time period corresponding to aduration of time for the step of curing.

Next, a top sheet 30 of the top sheet material 130 is sealed to a bottomsheet 40 of the bottom sheet material 140 around each insert 50 so as toform a border 22 along a perimeter of each insert 50 with the flatbedheat seal packager 108. Each insert 50 is positioned between the topsheet 30 and the bottom sheet 40, while the flatbed heat seal packager108 matches and aligns with the bottom sheet material 140 and now thetop sheet material 130 in the third direction 94. The flatbed heat sealpackager is 108 positioned along the bottom sheet material 140 in thethird direction 94 after the dispenser, and move in the third direction94 according to both the bottom sheet material 140, and the top sheetmaterial 130 in the third direction 94 during the step of sealing. Thesealing is usually performed in groups of inserts 50, so more than oneborder 22 is formed. A group of borders 22 are formed to seal a group ofinserts 50 within the flatbed heat seal packager 108.

The upper turn bar 101 and the upper rollers 109 align the top sheetmaterial 130 above the insert 50 and the bottom sheet material 140, andthe top sheet material 130 from the upper turn bar 101 to the flatbedheat seal packager 108 matches the bottom sheet material 140 from thelower turn bar 103 to the flatbed heat seal packager 108. The markingsand labels on the wrapper material 120 remain aligned.

Additionally, the flatbed heat seal packager 108 matches the top sheetmaterial 130 and the bottom sheet material 140 in the third direction 94during the step of sealing. In particular embodiments, the step ofmatching the flatbed heat seal packager 108 includes moving the flatbedheat seal packager 108 for a packaging time period. The packaging timeperiod corresponds to a duration of time for the step of sealing foreach border 22 and to a distance between the dispenser 106 and the sheetcutter 117. Eventually, the flatbed heat seal packager 108 separatesfrom the top sheet material 130 and the bottom sheet material 140. Then,the flatbed heat seal packager 108 is moved back in the second direction96 toward the dispenser 106 to align with another insert 50 upstreamfrom the sheet cutter 117.

The method further includes cutting each border 22 from the top sheetmaterial 130 and the bottom sheet material 140 with a sheet cutter 117so as to form an assembly 10 for each border 22, a perforated top sheetmaterial 131, and a perforated bottom sheet material 141. An outfeedconveyor 112 collects each assembly 10 and moves the assemblies 10 inthe third direction 94 away from the sheet cutter 117.

Embodiments of the method include additional steps, according tocomponents in the system 240.

With a third roll 104 below the second roll 102, the method includingrecovering the perforated foam material sheet 161. As part of the webconversion process, the perforated foam material sheet 161 should beaddressed to maintain alignment of the bottom sheet material 140 andfoam material 160 currently in the method. This embodiment includesconveying the perforated foam material 161 in the second direction 96away from the plurality of insert bodies 60 and between the foammaterial 160 and the bottom sheet material 140. The perforated foammaterial sheet 161 is stored on the third roll 104.

When the system 240 has an alignment means, the step of aligning theinsert body 60 can further include laying each insert body 60 on thebottom sheet material 140 while conveying the bottom sheet material 140in the third direction 94, and adhering each insert body 60 to thebottom sheet material 140. An alignment means may be a staticelectricity generator so that insert body 60 is removable adhered bystatic electric. Other alignment means, such as air puffs or adhesivesare also possible.

Embodiments of the method include detecting each insert body 60 by aposition scanner 111 so as to confirm alignment on the bottom sheetmaterial 140. A misaligned insert body can be identified and trackedthrough the system 240. The system 240 can control the dispenser 106 tonot deliver the set amount to the misaligned insert body or a rejectconveyor 118 can discard the bad assembly corresponding to themisaligned insert body.

FIGS. 7 and 10 also show a sprayer 113 as part of the dispenser 106. Themethod includes spraying the set amount or a plurality of set amounts ofthe chemical composition 200, 210, 220. Any pattern of chemicalcompositions 200, 210, 220 can be sprayed, even with the chemicalcompositions 200, 210, 220 being the same or different or anycombination thereof.

Embodiments of the method include another step in the web conversionprocess of the system 240. The method can include detecting each insertwith a first scanner 114 so as to confirm alignment on the bottom sheetmaterial 140, application or presence of the chemical composition 200,210, 220 on the insert body 60, and alignment of the chemicalcomposition 200, 210, 220 on the insert body 60, after the step ofdispensing. The first scanner 114 can be selected from a groupcomprising: a vision sensor, a splice sensor, and another sensor. Thefirst scanner 114 identifies a misapplied insert, just as the positionsensor 111 identifies a misaligned insert body. The misapplied insertcan be identified and tracked through the system 240. The system 240 cancontrol the flatbed heat seal packager 108 to not seal a border or thereject conveyor 118 can discard the bad assembly corresponding to themisapplied insert. The method includes detecting with more than onefirst scanner 114 also.

Embodiments of the method include still another step in the webconversion process of the system 240. The method can include detectingeach insert with a second scanner 116 so as to confirm the border 22 ofeach insert 50 before cutting. The second scanner 116 can be selectedfrom a group comprising: a photoelectric sensor, a vision sensor, asplice sensor, and another sensor. FIG. 12 shows the second scanner 116as a photoelectric sensor. The second scanner 116 identifies amis-sealed border, just as the position sensor 111 identifies amisaligned insert body. The mis-sealed border can be identified andtracked through the system 240. The system 240 can control the sheetcutter 117 to not cut or the reject conveyor 118 can discard the badassembly corresponding to the mis-sealed border. The method includesdetecting with more than one second scanner 116 also.

When the system 240 has a nip machine 115, the method can include anembodiment with the step of cutting an incision 26 in each border 22 soas to form a tab 24 for each border 22. The incision 26 can be withinthe border 22 so that the insert 50 remains sealed within the border 22,until the tab 24 breaches the border 22 and separates the top sheet 30and the bottom sheet 40. In this embodiment, the step of cutting theincision 26 is before the step of cutting each border 22.

FIGS. 7 and 12 also show embodiments of the system 240 with a fourthroll 110 below the outfeed conveyor 112. The corresponding embodiment ofthe method includes recovering the perforated top sheet material 131 andthe perforated bottom sheet material 141 together. As another part ofthe web conversion process, the perforated top sheet material 131 andthe perforated bottom sheet material 141 are addressed together tomaintain alignment of the top sheet material 130 and the bottom sheetmaterial 140. This embodiment includes conveying the perforated topsheet material 131 and the perforated bottom sheet material 141 in thesecond direction 96 away from the outfeed conveyor 112. The perforatedtop sheet material 131 and the perforated bottom sheet material 141 isstored on the fourth roll 110.

Additional embodiments of the method include the system 240 with apacking means 170 or a sorting means 180 or both. The method can includethe step of packing assemblies 10 from the outfeed conveyor 112. Thepacking means 170 can be connected to the outfeed conveyor 112 so thatthe assemblies 10 are placed into boxes or sleeves for transportmanually or by an automated machine. The method can also include sortingassemblies 10 from the outfeed conveyor 112 before the step of packingassemblies 10. The method divides and separates the assemblies 10 fromthe outfeed conveyor 112 into groups. The groups may be associated withpackaging for the packing means 170, such as packing a group of twelveassemblies 10 in one box. The groups may also be associated withdifferent chemical compositions 200, 210, 220. The scanners 111, 114,116 have detected the contents of the assemblies 10, and the markingsand labels on the top sheet 30 and the bottom sheet 40 are known. Thus,the sorting means 180 can be manual or any known automated machine, suchas a swivel arm and different sleeves for grouping.

FIGS. 7 and 12 also show embodiments of the method with a rejectconveyer 118. The reject conveyer 118 is positioned after the sheetcutter 117 in the third direction 94. The method includes the step ofrejecting assemblies identified as bad assemblies from any scanner 111,114, 116 with the reject conveyor 118. After the steps of detecting andmonitoring for any errors in the manufacturing process with the sensorsor scanners 111, 114, 116, the method includes maintaining and recordingthe position of each insert body 60, corresponding insert 50, andcorresponding assembly 10 in the system 240. The method further includestracking any error or anomaly detected as an insert body 60, an insert50, or assembly 10 as a tagged assembly. When that tagged assemblyreaches the reject conveyor 118, the method separates the taggedassembly from the other assemblies 10. The method of using the system240 detects errors and removes assemblies that do not meet qualitycontrol requirements. The method coordinates components of the system240 for accurate tracking and rejecting tagged assemblies with a rejectconveyor 118 as an automated quality control process.

Additional Relationships

The assembly 10 as an embodiment of the present invention furtherdescribes the method of manufacture. In this variation, the step ofcutting the foam material 160 into the plurality of insert bodies 60includes forming the insert body 60 of the assembly 10. Thus, the stepof cutting can further includes forming the insert body 60 havingrotational symmetry of at least four cyclic groups 66, wherein thehandle portion corresponds to only one cyclic group 66. Also, the stepof dispensing can further include positioning the set amount on theapplicator portion 64 and dividing the set amount between each cyclicgroup 66. The same variations to the method apply to the chemicalcomposition 200, 210, 220 being a cosmetic in the assembly 10. The stepof cutting can further include forming the insert body 60 havingrotational symmetry of at least four cyclic groups 66, wherein thehandle portion corresponds to only one cyclic group 66. Also, the stepof dispensing can further include positioning the set amount on theapplicator portion 64 and dividing the set amount between each cyclicgroup 66 for a single application of a cosmetic. With the embodiment ofthe assembly 10 with the chemical composition 200, 210, 220 as aplurality of different chemical compositions 200, 210, 220, the step ofdispensing can further include positioning each set amount on theapplicator portion 64 and positioning each set amount on a respectivecyclic group 66 separate from other cosmetics and another cyclic group66.

The chemical composition 200, 210, 220 as an embodiment of the presentinvention further describes the assembly 10. In these embodiments of theassembly 10, the insert 50 comprises the set amount of the chemicalcomposition 200, 210, 220 as claimed for a single dose or a singleapplication, when the chemical composition is a cosmetic. So, theembodiments of the assembly 10 now include a particular chemicalcomposition 200, 210, 220 on the insert body 60 having rotationalsymmetry of at least four cyclic groups 66, wherein the handle portioncorresponds to only one cyclic group 66. The set amount of theparticular chemical composition 200, 210, 220 is positioned on theapplicator portion 64 and divided between each cyclic group 66 of theapplicator portion 64.

In other embodiments of the assembly 10, there is a plurality of setamounts of chemical compositions 200, 210, 220 on the insert body 60,when the plurality of set amounts is required for a single dose orsingle application. Each set amount is positioned on the applicatorportion 64 is positioned, and each set amount is positioned on arespective cyclic group 66 separate from other cosmetics and anothercyclic group 66.

The chemical composition 200, 210, 220 as an embodiment of the presentinvention further describes the method to manufacture the assembly 10 aswell. The step of storing, the step of dispensing, and the step ofcuring are further modified by the chemical composition 200, 210, 220disclosed as an embodiment of the invention. The step of storing ismodified to include the particular chemical composition 200, 210, 220claimed, and the step of dispensing is modified to include theparticular chemical composition 200, 210, 220. The step of curing canalso be described as an alternate embodiment of the method tomanufacture. The step of curing can include adhering the chemicalcomposition 200, 210, 220 to the foam composition 230 or drying thechemical composition 200, 210, 220 on the foam composition 230 or both.

Between the step of dispensing the chemical composition 200, 210, 220and the step of sealing the top sheet 30, the chemical composition 200,210 220 has a rate of evaporation so as to dry between the step ofdispensing and the step of sealing the top sheet 30. The chemicalcomposition 200, 210, 220 is sealed in an active state for use when theassembly 10 is opened later. An amount of moisture is evaporated duringthis method so that there is the active state, when the assembly 10 isopened later.

In the method to manufacture the assembly 10 with the chemicalcomposition 200, 210, 220, chemical composition 200, 210, 220 has afirst amount of adhesion in the step of adhering and a second amount ofadhesion before the step of sealing the top sheet 30. The second amountof adhesion is less than the first amount of adhesion. Also, theconveyor time period of the step of conveying each insert 50 on thebottom sheet material 140 matches the step of drying the chemicalcomposition 200, 210, 220.

The foam composition 230 as an embodiment of the present inventionfurther describes both the assembly 10 and the method to manufacture theassembly 10.

In these embodiments of the assembly 10, the insert 50 comprises the setamount of the chemical composition 200, 210, 220 on the insert body 60as claimed for a single dose or a single application, when the chemicalcomposition is a cosmetic. So, the embodiments of the assembly 10 nowinclude a particular chemical composition 200, 210, 220 on the insertbody 60 with the foam composition 230 as claimed. The insert body 60still has rotational symmetry of at least four cyclic groups 66, whereinthe handle portion corresponds to only one cyclic group 66. The setamount of the particular chemical composition 200, 210, 220 is stillpositioned on the applicator portion 64 and divided between each cyclicgroup 66 of the applicator portion 64, wherein the applicator portion 64is made of the foam composition 230 as claimed.

In other embodiments of the assembly 10, there is a plurality of setamounts of chemical compositions 200, 210, 220 on the insert body 60 ofthe claimed foam composition 230, when the plurality of set amounts isrequired for a single dose or single application. Each set amount ispositioned on the applicator portion 64 is positioned, and each setamount is positioned on a respective cyclic group 66 separate from othercosmetics and another cyclic group 66, wherein the applicator portion 64is made of the foam composition 230 as claimed.

The foam composition 230 as an embodiment of the present inventionfurther describes the method to manufacture the assembly 10 similar tohow the chemical composition 200, 210, 220 described the method. Thestep of dispensing and the step of curing are further modified by thefoam composition 230 interacting with the chemical composition 200, 210,220 disclosed as an embodiment of the invention. The step of dispensingis modified to include the particular chemical composition 200, 210, 220on the insert body 60 of the foam composition 230 as claimed. The stepof curing can also be described as an alternate embodiment of the methodto manufacture. The step of curing can include adhering the chemicalcomposition 200, 210, 220 to the foam composition 230 or drying thechemical composition 200, 210, 220 on the foam composition 230 or both.

Between the step of dispensing the chemical composition 200, 210, 220and the step of sealing the top sheet 30, the chemical composition 200,210 220 has a rate of evaporation so as to dry on the insert body 60 ofthe foam composition 230 between the step of dispensing and the step ofsealing the top sheet 30. The chemical composition 200, 210, 220 issealed in an active state for use when the assembly 10 is opened later.An amount of moisture is evaporated during this method so that there isthe active state, when the assembly 10 is opened later.

In the method to manufacture the assembly 10 with the chemicalcomposition 200, 210, 220 on the insert body of the foam composition230, chemical composition 200, 210, 220 has a first amount of adhesionin the step of adhering and a second amount of adhesion before the stepof sealing the top sheet 30. The second amount of adhesion is less thanthe first amount of adhesion. Also, the conveyor time period of the stepof conveying each insert 50 on the bottom sheet material 140 matches thestep of drying the chemical composition 200, 210, 220.

The present invention delivers a cosmetic, health or hygiene chemicalcomposition in an active state, after being packaged and stored in adisposable single use assembly. The assembly itself is portable andconvenient for storing in bulk or transporting individually in a purseor pocket. The assembly aligns the applicator as an insert body withinthe wrapper, so that the applicator portion with the chemicalcomposition is stabilized. The border of the wrapper holds the insert inposition within the wrapper so that the chemical composition is notspread all over the insert. The handle portion remains isolated andclean. When the assembly is opened, the handle portion is available foruse, without getting the chemical composition on fingers or hands.

The relationship between the insert and the wrapper provides a cosmetic,health or hygiene chemical composition on an applicator for delivery inan active state to the user. The active state is preserved, even afterthe manufacturing process and storage in the assembly. The active stateis also preserved for each chemical composition, when there is more thanone chemical composition on the insert, such as an assembly withdifferent cosmetics on each insert. The insert, border, and wrapper canalso preserve the active state of more than one cosmetic in the sameassembly. The applicator assembly of the present invention stores andcarries cosmetics in a simple, easy, and inexpensive container.

The present invention includes the chemical composition compatible withthe assembly. A set amount of the chemical composition is stored in eachassembly, and the chemical composition can be a cosmetic or severaldifferent cosmetics. The set amount corresponds to a single dose, or asingle application for when the chemical composition is a cosmetic. Thechemical composition is compatible with the manufacturing process of theassembly. The active state of the chemical composition is maintainedduring the step of dispensing the set amounts on each insert and thestep of curing on each insert before the step of sealing. Any drying ordegradation of the chemical composition is coordinated with themanufacturing process. Additionally, the chemical composition iscompatible with the assembly and the relationship between the insert,border, and wrapper. The chemical composition can be applied to theinsert as required to maintain the alignment within the wrapper topreserve the active state.

The present invention includes the foam composition. The insert body ismade of the foam composition. The insert body is important to hold thechemical composition within the assembly, and the insert body must alsobe compatible with the manufacturing process so that the chemicalcomposition on the insert body can maintain an active state in theassembly. The assembly may be stored and transported for an extendedperiod of time, such as months and maybe years. The foam compositionmust remain durable, so that the insert can administer the chemicalcomposition, even after such time has passed. The foam composition mustbe compatible with use as an insert body to administer the chemicalcomposition, in addition to maintaining the active state of the chemicalcomposition in the manufacturing process and keeping alignment withinthe assembly.

The active state of the chemical composition is further maintainedduring the step of dispensing the set amounts on the foam composition ofeach insert and the step of curing on the foam composition of eachinsert before the step of sealing. The chemical composition must be ableto adhere to the foam composition, in addition to maintaining an activestate. Any drying or degradation of the chemical composition on the foamcomposition is also coordinated with the manufacturing process.Additionally, the foam composition is compatible with the assembly andthe relationship between the insert, border, and wrapper. The foamcomposition supports the chemical composition in place and has rigidityto maintain the alignment within the wrapper to preserve the activestate. Furthermore, after extended time, the foam composition isresilient to be used to administer the chemical composition, wheneverthe assembly is opened for use.

The present invention includes the system and method to manufacture theassembly. The process as a web conversion process must account for thealignment and tracking of web materials. The system must set thecomponents in position to complete the sequence. In the presentinvention, there are additional considerations for the position to othercomponents, sequence, timing, and distance for the particular chemicalcomposition and foam composition for the assembly. The method includesan orthogonal dispensing of the wrapper material and split into twodirections of the top sheet material and the bottom sheet material. Thesystem includes the turn bars and rollers to accomplish this sequence.The top sheet material is matched back to the bottom sheet material atthe sealing stage. Additionally, the step of dispensing the chemicalcomposition is matched in the third direction, according to time todispense and distance to the flatbed heat seal packager. The sequencefor the drying and curing of the chemical composition to remain in theactive state is compatible for the chemical composition and foamcomposition as claimed. The time between dispensing and sealing candeliver the cosmetic, health, or hygiene chemical composition in anactive state to the user. Furthermore, the placement of the foam cutterand the sheet cutter maintains alignment of the insert within thewrapper.

The embodiments of the present invention provide an applicator assemblyfor disposable single use. In order to maintain the active state of thechemical composition in the assembly, the present invention includes thealignment of components of the assembly and the manufacturing processfor the assembly. Additionally, the chemical composition and foamcomposition are embodiments for the system and method of manufacturingthe assembly.

The foregoing disclosure and description of the invention isillustrative and explanatory thereof. Various changes in the details ofthe illustrated structures, construction and method can be made withoutdeparting from the true spirit of the invention.

I claim:
 1. A foam composition for storing and transport, comprising areaction product of water, clay, polyacrylate, silane, methanol,ethylenediamine, and polyurethane prepolymer, said foam compositionbeing hydrophilic with a melting point greater than 3 F and a specificgravity of 0.3 to 0.5.
 2. An assembly for storing and transporting, saidassembly comprising: a wrapper having a top sheet and a bottom sheet,said top sheet being sealed to said bottom sheet so as to form a borderalong a perimeter of said top sheet and said bottom sheet; and an inserthaving a top surface and a bottom surface, said insert being comprisedof an insert body with a handle portion and an applicator portion,wherein said insert body is positioned between said top sheet and saidbottom sheet, wherein said insert body is comprised of said foamcomposition, according to claim 1, wherein said border aligns with saidapplicator portion only so as to maintain said insert in place withinsaid wrapper, wherein said insert further comprises: a set amount of achemical composition, corresponding to a single dose, and wherein saidset amount is positioned on said applicator portion, wherein said insertbody has rotational symmetry having at least four cyclic groups, andwherein said handle portion corresponds to only one cyclic group,wherein said set amount is divided between each cyclic group of saidapplicator portion, and wherein said chemical composition comprises:55-70 weight percent of amorphous silica; 4-12 weight percent of a whiteadhesive agent; 1—weight percent of a coloring agent; and 0.5-4.0 weightpercent a first aromatic preservative agent.
 3. The assembly, accordingto claim 2, wherein said chemical composition is a cosmetic.
 4. Anassembly for storing and transporting, said assembly comprising: awrapper having a top sheet and a bottom sheet, said top sheet beingsealed to said bottom sheet so as to form a border along a perimeter ofsaid top sheet and said bottom sheet; and an insert having a top surfaceand a bottom surface, said insert being comprised of an insert body witha handle portion and an applicator portion, wherein said insert body ispositioned between said top sheet and said bottom sheet, wherein saidinsert body is comprised of said foam composition, according to claim 1,wherein said border aligns with said applicator portion only so as tomaintain said insert in place within said wrapper, wherein said insertfurther comprises: a plurality of set amounts of a plurality of chemicalcompositions, said plurality of set amounts corresponding to a singledose, wherein each chemical composition comprises: 55-70 weight percentof amorphous silica; 4-12 weight percent of a white adhesive agent;1—weight percent of a coloring agent; and 0.5-4.0 weight percent a firstaromatic preservative agent, wherein each set amount is positioned onsaid applicator portion, wherein said insert body has rotationalsymmetry having at least four cyclic groups, wherein said handle portioncorresponds to only one cyclic group, and wherein each set amount ispositioned on a corresponding cyclic group of said applicator portion.5. The assembly, according to claim 4, wherein each chemical compositionis a cosmetic, and wherein each cosmetic is positioned on a respectivecyclic group of said applicator portion separate from other cosmetics.6. A method of manufacturing, comprising the steps of: mounting a firstroll of wrapper material; dispensing said wrapper material in a firstdirection; splitting said wrapper material into a top sheet material anda bottom sheet material; conveying said bottom sheet material in asecond direction orthogonal to said first direction by a lower turn bar;conveying said top sheet material in a third direction orthogonal tosaid first direction and opposite to said second direction by an upperturn bar; mounting a second roll of foam material orthogonal to saidfirst roll, said form material being comprised of said foam composition,according to claim 1; dispensing said foam material in said thirddirection; switching said top sheet material between said thirddirection and said second direction by a plurality of upper rollers;switching said bottom sheet material between said second direction andsaid third direction by a plurality of lower rollers; matching said foammaterial and said second sheet material in said third direction at afoam cutter aligned with said second roll, said foam material beingabove said bottom sheet material; cutting said foam material into aplurality of insert bodies and a perforated foam material sheet withsaid foam cutter; aligning each insert body on said bottom sheetmaterial while matching said bottom sheet material in said thirddirection; storing said chemical composition, in a dispenser positionedafter the step of cutting said foam material, wherein said dispenser ispositioned above each insert body and said bottom sheet material andafter said foam cutter, wherein said chemical composition comprises:55-70 weight percent of amorphous silica; 4-12 weight percent of a whiteadhesive agent; 1—weight percent of a coloring agent; and 0.5-4.0 weightpercent a first aromatic preservative agent; dispensing said chemicalcomposition from said dispenser on each insert body while matching saidbottom sheet material in said third direction, so as to form an insert,corresponding to each insert body; matching said dispenser to saidbottom sheet material in said third direction, said step of matchingsaid dispenser being comprised of: moving said dispenser across saidbottom sheet material and over each insert body for a delivery timeperiod, said delivery time period corresponding to a duration of timefor the step of dispensing to each insert body so as to form eachinsert; and aligning said dispenser with another insert body upstreamtoward said foam cutter by moving in said second direction, after saiddelivery time period of the step of dispensing; curing said chemicalcomposition on said foam material of said insert body, said foammaterial being comprised of a foam composition; conveying each insert onsaid bottom sheet material for a conveyer time period away from saiddispenser, said conveyor time period corresponding to a duration of timefor the step of curing; sealing a top sheet of said top sheet materialto a bottom sheet of said bottom sheet material around each insert so asto form a border along a perimeter of each insert with a flatbed heatseal packager, each insert being positioned between said top sheet andsaid bottom sheet, while said flatbed heat seal packager matches saidbottom sheet material and said top sheet material in said thirddirection, wherein said flatbed heat seal packager is positioned alongsaid bottom sheet material in said third direction after said dispenser,said flatbed heat seal packager being movable in said third direction soas to match said bottom sheet material and said top sheet material insaid third direction, and wherein said upper turn bar and said upperrollers align said top sheet material above said insert and said bottomsheet material, said top sheet material from said upper turn bar to saidflatbed heat seal packager matching said bottom sheet material from saidlower turn bar to said flatbed heat seal packager; matching said flatbedheat seal packager to said top sheet material and said bottom sheetmaterial in said third direction; cutting each border from said topsheet material and said bottom sheet material with a sheet cutter so asto form an assembly, according to claim 1, for each border, a perforatedtop sheet material, and a perforated bottom sheet material; andcollecting each assembly on an outfeed conveyor, said outfeed conveyormoving in said third direction away from said sheet cutter.
 7. Themethod of manufacturing, according to claim 6, wherein the step ofcuring said chemical composition comprises: adhering said chemicalcomposition to said foam composition; and drying said chemicalcomposition on said foam composition, between the step of dispensingsaid chemical composition and the step of sealing said top sheet,wherein said chemical composition has a rate of evaporation so as to drybetween the step of dispensing said chemical composition and the step ofsealing said top sheet.
 8. The method of manufacturing, according toclaim 7, wherein said chemical composition has a first amount ofadhesion in the step of adhering and a second amount of adhesion beforethe step of sealing said top sheet, said second amount of adhesion beingless than said first amount of adhesion.
 9. The method of manufacturing,according to claim 8, wherein said conveyor time period of the step ofconveying each insert on said bottom sheet material matches the step ofdrying.